Ford 8.8 Pinion Seal Replacement Using DATA! - Perfectly Set and Easy! - Vortex Garage

Our 2003 Lincoln Town Car had a leaking pinion seal - so was time to replace. You can find many guides on YouTube for this, but not many that go over Factory Service Manual steps and show how to record and deal with preload data using an inexpensive tool.

Scroll down past tools/parts links for torque specs and addtl data.

NOTE: Amazon links go to my Amazon Affiliates link, and I may get a small amount from that. I post links to tools and parts I have used or alternatives if discontinued that I would order if I were doing this at time of posting.

For parts, I HIGHLY RECOMMEND using OEM! I have had GREAT luck with Varsity Ford's parts department and online team - so I'm using them for my OEM parts links.

PARTS:

DL3Z-4851-A Companion Flange
https://www.varsityfordparts.com/oem-...

BR3Z-4676-A Pinion Seal
https://www.varsityfordparts.com/oem-...

7L1Z-4635-B OEM Ford UJoints (2 needed)
https://www.varsityfordparts.com/oem-...

Alternative:
MOOG 345 U-joint (2 needed)
https://amzn.to/3yipTA5

Allstar ALL72155 Pinion Nut for Ford 8.8"
https://amzn.to/3jjev0H

Optional if leaking:
4R70W Transmission Extension Housing Seal - Ford (7W7Z-7052-A)
https://www.varsityfordparts.com/oem-...

Genuine Ford XY-80W90-QL SAE 80W-90 - 1 Quart
https://amzn.to/3lxlbuH
This says it works on LSD's, but if you need it:
Genuine Ford Fluid XL-3 Friction Modifier Additive - 4 oz.
https://amzn.to/3ltoiE4

Permatex Ultra Grey RTV:
https://amzn.to/3fuZk3b

TOOLS:

Lisle 56750 Seal Puller
https://amzn.to/3ypf3rV

ARES 70213 - 1/4-inch Drive Beam Torque Wrench
https://amzn.to/3ltoSkY
Alternative:
Titan 23140 1/4 Drive Beam Torque Wrench
https://amzn.to/3fsCJV2

uxcell 1/4 Inch Drive (F) x 1/2 Inch (M) Socket Adapter
https://amzn.to/3ilJJ85

Dewalt 1/2" Drive Socket, 1-1/16"
https://amzn.to/3xklZFv

TEKTON 1/2 Inch Drive Click Torque Wrench (10-150 ft.-lb.) | 24335
https://amzn.to/3xokdDt

OTC 4531 Harmonic Balancer Puller and Installer Set
https://amzn.to/3zYITnI
Harbor Freight Version:
https://www.harborfreight.com/harmoni...

Astro Pneumatic Tool 7868 Master Ball Joint Adapter Set (This may be the new version of mine)
https://amzn.to/3fsNKG1

Mission Auto - Pinion Yoke Holder Tool
(I don't have this but it claims to fit Ford - may want to research before buy)
https://amzn.to/3rPPKgr

ABN 6in 3-Jaw Gear Puller
https://amzn.to/3ymMT0T

M12 Hex Bolt M12-1.75 x 25mm - 5pcs
https://amzn.to/3xt5JSU

Ford Driveshaft Yoke Bolts N800594S100 (I used my old ones)
https://amzn.to/3Cf2vFW

Forney 70822 Marker, Paint, Yellow
https://amzn.to/3rYPknV

Capri Tools 1/2 in. Drive 30 in. Extended Leverage Breaker Bar
https://amzn.to/3joif0T

GEARWRENCH 1/2" Drive 120XP Flex Head Ratchet - 81306P
https://amzn.to/3jqb08O

This could take the role of both breaker bar and ratchet:
GEARWRENCH 1/2" Drive 84 Tooth Flex Head Ratchet 24" - 81363A-07
https://amzn.to/2TTo11R

Socket Sets - a bit pricey but great to have!

GEARWRENCH 84935 1/2-Inch Drive Impact Socket Set Deep Metric
https://amzn.to/37kZghY

GEARWRENCH 19 Piece 1/2 Inch Drive 6 Point Impact Socket Set, Deep
https://amzn.to/2TRenN4

You'll need a 21mm for lugnuts, 1-1/6 for pinion nut, and whatever your puller/installer tools use.

Sunex International 312ZUM 3/8" Dr. 12mm 12 Point Universal Impact Socket for Ford Driveshafts
https://amzn.to/3fp6nu7
or...
GEARWRENCH 3/8" Drive Standard Metric Socket 12mm, 12 Point - 80488
https://amzn.to/2Vl5yMf


CRC 05090 Brakleen (1Gal)
https://amzn.to/2TToX6n

Vaper 19419 Red Spot Spray Non-Aerosol Sprayer (Red) - 32 oz.
https://amzn.to/2Vi7Ewg

Torque Specs:

DS Bolts: 83 lb ft
Wheel lug nuts - 85-105lb ft
Caliper bolts (rear only) - 18lb ft


Service Manual availabe at: alldatadiy.com

Key steps for bearing settings:

CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut.

CAUTION: Remove the special tool while taking preload readings with the Nm (inch-pound) torque wrench.

Use the special tool to hold the pinion flange while tightening the nut.
Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch-pound) torque wrench.
If the preload recorded prior to disassembly is lower than the specification for used bearings, tighten the nut to specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, tighten the nut to the original reading as recorded.
Refer to specifications for used pinion bearings.

Torque specs:
Differential pinion bearing preload (used pinion hearings,) 0.9-1.5 Nm (8-14 inch lbs.)
Differential pinion bearing preload (new pinion bearings) 1.8-3.3 Nm (16-29 inch lbs.)